Combined Power and Communications Cable for Industrial Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial control systems require multiple cables for power delivery and communication, leading to increased complexity, cost, and susceptibility to electromagnetic interference, which affects signal integrity and data loss.
Innovation Solution
A combined power and communications cable with separate groups for power and data signals, utilizing insulation with low dielectric constant, strategic conductor placement, and electrical shielding to minimize noise and interference, while maintaining a reduced cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If separate power cables and communication cables are used, then electromagnetic interference between power signals and data signals is minimized, but the system complexity and cable quantity increase
Solution Approach 1:
The patent combines power delivery conductors and communication conductors into a single cable assembly, reducing the total number of cables and connectors while maintaining electromagnetic interference protection through internal shielding and strategic conductor placement
2Reliability
If multiple separate cables are used for power and communication, then signal integrity is maintained, but installation complexity and cost increase
Solution Approach 1:
The cable integrates multiple functions (power delivery, communication, shielding) into a single assembly with standardized connectors, reducing installation steps and complexity while maintaining signal integrity through protected conductor routing
Solution Approach 2:
The single cable performs multiple functions simultaneously: delivering high-voltage power, transmitting low-voltage communication signals, providing electromagnetic shielding, and offering mechanical protection, all through one universal connector interface
3Area of stationary object
If power and communication conductors are placed close together in a single cable, then cable cross-section is reduced, but noise and interference on data signals increase
Solution Approach 1:
The cable internally segments conductors into separate groups: high-voltage power conductors and low-voltage communication conductors, with shielding layers positioned between them to maintain compact cross-section while preventing electromagnetic coupling and interference
Solution Approach 2:
Electromagnetic shielding layers act as intermediary barriers between power and communication conductors, blocking electromagnetic fields and preventing noise coupling while allowing the cable to maintain a compact integrated structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces noise and interference on data signals, improves handling, and decreases manufacturing costs by minimizing the cable's cross-sectional area, maintaining signal integrity and reducing signal distortion.
Implementation Method 1
The fourth and fifth insulated conductors are twisted together and covered by an electrical shield
Implementation Method 2
The fourth and fifth insulated conductors are twisted together
Data Source
AI summary
Aspects of the present invention provide an improved cable having a reduced cross section while continuing to provide high voltage (noisy) power signals alongside low voltage (noise-susceptible) data signals. The improved cable can be used for power delivery and communications between a motor and a drive in an industrial control system. The reduced cross section advantageously improves handling. By providing separate groups between a group delivering the power signals and a group providing the data signals, thereby enforcing a physical separation, and by twisting together individual conductors of the group delivering the power signals with the group providing the data signals and the groups providing the separation, the reduced cross section can be achieved while continuing to minimize noise and interference onto the data signals due to the power signals.